Smokeless tobacco pastille and injection molding process for forming smokeless tobacco products

ABSTRACT

A smokeless tobacco composition configured for insertion into the mouth of a user is provided. The smokeless tobacco composition includes a tobacco material and a polysaccharide filler component such as polydextrose. A process for preparing a smokeless tobacco composition pastille configured for insertion into the mouth of a user is also provided. The process includes mixing a tobacco material with a binder and a polysaccharide filler component to form a smokeless tobacco mixture, injection molding the smokeless tobacco mixture, and cooling the smokeless tobacco mixture to form a solidified smokeless tobacco composition pastille. The mixing step can include forming a dry blend of the tobacco, filler, and binder components, and combining the dry blend with a viscous liquid component. The injection-molded pastille can provide a dissolvable and lightly chewable product.

FIELD OF THE DISCLOSURE

The present disclosure relates to products made or derived from tobacco,or that otherwise incorporate tobacco, and are intended for humanconsumption. In particular, the disclosure relates to compositions orformulations incorporating tobacco, and that are intended to be employedin a smokeless form.

BACKGROUND OF THE DISCLOSURE

Cigarettes, cigars, and pipes are popular smoking articles that employtobacco in various forms. Such smoking articles are employed by heatingor burning tobacco to generate aerosol (e.g., smoke) that may be inhaledby the smoker. Tobacco may also be enjoyed in a so-called “smokeless”form. Particularly popular smokeless tobacco products are employed byinserting some form of processed tobacco or tobacco-containingformulation into the mouth of the user. See for example, the types ofsmokeless tobacco formulations, ingredients, and processingmethodologies set forth in U.S. Pat. No. 1,376,586 to Schwartz; U.S.Pat. No. 3,696,917 to Levi; U.S. Pat. No. 4,513,756 to Pittman et al.;U.S. Pat. No. 4,528,993 to Sensabaugh, Jr. et al.; U.S. Pat. No.4,624,269 to Story et al.; U.S. Pat. No. 4,991,599 to Tibbetts; U.S.Pat. No. 4,987,907 to Townsend; U.S. Pat. No. 5,092,352 to Sprinkle, IIIet al.; U.S. Pat. No. 5,387,416 to White et al.; U.S. Pat. No. 6,668,839to Williams; U.S. Pat. No. 6,834,654 to Williams; U.S. Pat. No.6,953,040 to Atchley et al.; U.S. Pat. No. 7,032,601 to Atchley et al.;and U.S. Pat. No. 7,694,686 to Atchley et al.; U.S. Pat. Pub. No.2004/0020503 to Williams; U.S. Pat. Pub. No. 2005/0115580 to Quinter etal.; U.S. Pat. Pub. No. 2005/0244521 to Strickland et al.; U.S. Pat.Pub. No. 2006/0191548 to Strickland et al.; u.S. Pat. Pub. No.2007/0062549 to Holton, Jr. et al.; U.S. Pat. Pub. No. 2007/0186941 toHolton, Jr. et al.; U.S. Pat. Pub. No. 2007/0186942 to Strickland etal.; U.S. Pat. Pub. No. 2008/0029110 to Dube et al.; U.S. Pat. Pub. No.2008/0029116 to Robinson et al.; U.S. Pat. Pub. No. 2008/0029117 to Muaet al.; U.S. Pat. Pub. No. 2008/0173317 to Robinson et al.; U.S. Pat.Pub. No. 2008/0196730 to Engstrom et al.; U.S. Pat. Pub. No.2008/0209586 to Neilsen et al.; U.S. Pat. Pub. No. 2008/0305216 toCrawford et al.; U.S. Pat. Pub. No. 2009/0065013 to Essen et al.; U.S.Pat. Pub. No. 2009/0293889 to Kumar et al.; and U.S. Pat. Pub. No.2010/0291245 to Gao et al.; PCT WO 04/095959 to Arnarp et al.; and WO2010/132444 A2 to Atchley; and U.S. patent application Ser. No.12/638,394, filed Dec. 15, 2009, to Mua et al.; each of which isincorporated herein by reference. Exemplary smokeless tobacco productsthat have been marketed include those referred to as CAMEL Snus, CAMELOrbs, CAMEL Strips and CAMEL Sticks by R. J. Reynolds Tobacco Company;GRIZZLY moist tobacco, KODIAK moist tobacco, LEVI GARRETT loose tobaccoand TAYLOR'S PRIDE loose tobacco by American Snuff Company, LLC; KAYAKmoist snuff and CHATTANOOGA CHEW chewing tobacco by SwisherInternational, Inc.; REDMAN chewing tobacco by Pinkerton Tobacco Co. LP;COPENHAGEN moist tobacco, COPENHAGEN Pouches, SKOAL Bandits, SKOALPouches, RED SEAL long cut and REVEL Mint Tobacco Packs by U.S.Smokeless Tobacco Company; and MARLBORO Snus and Taboka by Philip MorrisUSA.

It would be desirable to provide an enjoyable form of a tobacco product,such as a smokeless tobacco product, and to provide processes forpreparing tobacco-containing compositions suitable for use in smokelesstobacco products.

SUMMARY OF THE DISCLOSURE

The present disclosure relates to a dissolvable smokeless tobaccopastille product configured for insertion into the mouth of a user andprocesses for preparing a smokeless tobacco composition suitable for usein a smokeless tobacco product. The smokeless tobacco composition of thedisclosure utilizes a polysaccharide filler component to provide adissolvable smokeless tobacco product having a lightly chewable qualityin the form of an injection-molded pastille. In one embodiment, thesmokeless tobacco product is in the form of a solid object having atobacco material (e.g., particulate tobacco material) and apolysaccharide filler component. The smokeless tobacco compositionpreferably includes a polysaccharide filler component and tobacco ingranular or particulate form, or in the form of a liquid or dehydratedtobacco extract, and may include other ingredients, such as sweeteners,binders, emulsifiers, additional fillers, flavoring agents, anddisintegration aids. According to one aspect, the tobacco materialincludes tobacco particles having an average particle size of less thanabout 100 microns, less than about 75 microns, typically less than about50 microns, and most often an average particle size of about 25 microns.

In one aspect, the disclosure provides a smokeless tobacco pastilleproduct configured for insertion into the mouth of a user of theproduct, the smokeless tobacco pastille product comprising a tobaccomaterial and a polysaccharide filler component. Suitable polysaccharidefiller components for providing a smokeless tobacco pastille product inaccordance with the present disclosure include polydextrose,maltodextrin, pullulan, and mixtures thereof.

The smokeless tobacco composition can further include one or moreadditives, such as flavorants, additional fillers, binders, emulsifiers,humectants, syrups, disintegration aids, and mixtures thereof. Certainembodiments of the smokeless tobacco product of the invention includebinders (e.g., gum arabic or other water soluble gums), humectants(e.g., corn syrup), sugar alcohols (e.g., sorbitol), artificialsweeteners (e.g., sucralose), flavorants, salts (e.g., sodium chloride),or combinations thereof.

Although relative amounts of the various components can vary, thesmokeless tobacco compositions of the invention will typically compriseabout 10 weight percent to about 25 weight percent of the polysaccharidefiller component on a dry weight basis. In one embodiment, the smokelesstobacco composition includes at least about 20 dry weight percent oftobacco material, based on the total weight of the composition; at leastabout 10 dry weight percent of polysaccharide filler component; at leastabout 10 dry weight percent of at least one binder; at least about 20dry weight percent of at least one humectant; at least about 1 dryweight percent of at least one emulsifier; at least about 0.1 dry weightpercent of at least one sweetener; and at least about 0.5 dry weightpercent of at least one flavorant.

In yet another aspect, the disclosure provides a process for preparing asmokeless tobacco composition pastille configured for insertion into themouth of a user, comprising mixing a tobacco material (e.g., particulatetobacco material) with a binder and a polysaccharide filler component toform a smokeless tobacco mixture; injection molding the smokelesstobacco mixture (e.g., by compressing the smokeless tobacco mixtureusing a compressive force of at least about 75,000 kPa or at least about100,000 kPa); and cooling the smokeless tobacco mixture to form asolidified smokeless tobacco composition pastille (e.g., cooling to atemperature of about 20° C. to about 25° C.).

In one embodiment, the mixing step comprises forming a dry blendcomprising a mixture of the tobacco material, the binder, and thepolysaccharide filler component, and combining the dry blend with aliquid component to form the smokeless tobacco mixture. It isadvantageous for all components of the dry blend to have a relativelylow moisture content (e.g., less than about 5 weight percent moisture)and to have a relatively uniform particle size (e.g., less than about 50microns). If desired, the dry blend can further comprise a salt, asweetener, or a combination thereof. The liquid component is typically ahighly viscous liquid at either room temperature or when heated to anelevated temperature (e.g., about 40° C. to about 150° C.), and willtypically contain one or more humectants, emulsifiers, gelling agents,syrups, or combinations thereof.

In certain embodiments, the process can include adding an additive tothe tobacco material prior to the mixing step. Exemplary additivesinclude flavorants, emulsifiers, disintegration aids, humectants, andmixtures thereof.

In certain embodiments, prior to the injection molding process, thesmokeless tobacco mixture is extruded into an extruded form, and thensubjected to grinding in order to produce a powder granulation. Theextruded, ground composition can be loaded into the injection mold forsubsequent molding into final product form.

Aspects of the present disclosure thus provide advantages as otherwisedetailed herein.

DETAILED DESCRIPTION

The present disclosure now will be described more fully hereinafter. Thedisclosure may be embodied in many different forms and should not beconstrued as limited to the aspects set forth herein; rather, theseaspects are provided so that this disclosure will satisfy applicablelegal requirements. As used in this specification and the claims, thesingular forms “a,” “an,” and “the” include plural referents unless thecontext clearly dictates otherwise.

The invention provides a smokeless tobacco composition suitable for oraluse. The smokeless tobacco composition generally includes a tobaccomaterial formulation and one or more additional components that combineto form a dissolvable and lightly chewable smokeless tobacco pastilleproduct. As used herein, the term “pastille” refers to a dissolvableoral product made by solidifying a liquid or gel composition, such as acomposition that includes a gelling or binding agent, so that the finalproduct is a hardened solid gel. As used herein, the terms “dissolve,”“dissolving,” and “dissolvable” refer to compositions havingaqueous-soluble components that interact with moisture in the oralcavity and enter into solution, thereby causing gradual consumption ofthe product. In certain embodiments, the products of the invention arecharacterized by sufficient cohesiveness to withstand light chewingaction in the oral cavity without rapidly disintegrating. The productsof the invention typically do not exhibit a highly deformable chewingquality as found in conventional chewing gum.

In certain embodiments, advantageous organoleptic properties of theproducts of the invention can be attributed to the presence of apolysaccharide filler component. These carbohydrate materials typicallycomprise one or more polysaccharides containing multiple monosaccharideunits. Exemplary monosaccharide units include xylose, ribose, fructose,glucose (e.g., dextrose), maltose, and mannose. The number averagemolecular weight of the polysaccharide can vary, but is typically about1,000 Da to about 20,000 Da, more often about 2,000 Da to about 10,000Da. Exemplary polysaccharides include polydextrose, maltodextrin, andpullulan. One source of maltodextrin is MALTRIN M100 from GrainProcessing Corporation.

Polydextrose is primarily composed of a polymer comprising dextroseunits with minor amounts of a polyol (e.g., sorbitol) and an edible acid(e.g., citric acid). Polydextrose is typically made by acid-catalyzedpolymerization of dextrose units using, if desired, a polyol as a chainterminating agent. Exemplary edible acids include various mineral acidsand carboxylic acids. Polydextrose can be made using, for example, theprocess set forth in U.S. Pat. No. 5,601,863 to Borden et al., which isincorporated by reference herein. Polydextrose can be described as asoluble fiber bulking agent, and polydextrose may also exhibithumectant-like properties. Exemplary sources of polydextrose includeLITESSE polydextrose (available from Danisco A/S), STA-LITE polydextrose(available from Tate & Lyle Ingredients Americas, Inc.), and TRIMCALpolydextrose (available from C and H Ingredients Ltd). In oneembodiment, the polydextrose is combined with a second polysaccharidecomponent such as maltodextrin or pullulan.

The polysaccharide filler component used for the manufacture of thesmokeless tobacco product preferably is provided in a ground,granulated, fine particulate, or powder form. Preferably, thepolysaccharide filler component is employed in the form of parts orpieces that have an average particle size less than about 100 microns,and more preferably less than about 50 microns.

The relative amount of polysaccharide filler component within thesmokeless tobacco composition may vary. Preferably, the amount ofpolysaccharide filler component within the smokeless tobacco compositionis at least about 5 percent or at least about 10 percent or at leastabout 15 percent, on a dry weight basis of the composition. An exemplaryweight range is about 5 to about 50 weight percent, more often about 10to about 25 weight percent.

The moisture content of the polysaccharide filler component prior tomixing with the tobacco material formulation may vary. Most preferably,the moisture content of the polysaccharide filler component is less thanabout 10 weight percent, and may be less than about 5 percent, and isoften less than about 2.5 weight percent.

The products of the invention incorporate some form of a plant of theNicotiana species, and most preferably, those compositions or productsincorporate some form of tobacco. The selection of the Nicotiana speciescan vary; and in particular, the selection of the types of tobacco ortobaccos may vary. Tobaccos that can be employed include flue-cured orVirginia (e.g., K326), burley, sun-cured (e.g., Indian Kurnool andOriental tobaccos, including Katerini, Prelip, Komotini, Xanthi andYambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g.,Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g.,North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian andRustica tobaccos, as well as various other rare or specialty tobaccos.Descriptions of various types of tobaccos, growing practices andharvesting practices are set forth in Tobacco Production, Chemistry andTechnology, Davis et al. (Eds.) (1999), which is incorporated herein byreference. Various representative other types of plants from theNicotiana species are set forth in Goodspeed, The Genus Nicotiana,(Chonica Botanica) (1954); U.S. Pat. No. 4,660,577 to Sensabaugh, Jr. etal.; U.S. Pat. No. 5,387,416 to White et al. and U.S. Pat. No. 7,025,066to Lawson et al.; U.S. Patent Appl. Pub. No. 2006/0037623 to Lawrence,Jr. and U.S. Pat. Appl. Pub. No. 2008/0245377 to Marshall et al.; eachof which is incorporated herein by reference. Exemplary Nicotianaspecies include N. tabacum, N. rustica, N. alata, N. arentsii, N.excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N.kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N.sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. xsanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis,N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N.occidentalis, N. paniculata,

N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N.stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides,N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N.clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii,N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalissubsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N.repanda, N. rotundifolia, N. solanifolia, and N. spegazzinii.

Nicotiana species can be derived using genetic-modification orcrossbreeding techniques (e.g., tobacco plants can be geneticallyengineered or crossbred to increase or decrease production ofcomponents, characteristics or attributes). See, for example, the typesof genetic modifications of plants set forth in U.S. Pat. No. 5,539,093to Fitzmaurice et al.; U.S. Pat. No. 5,668,295 to Wahab et al.; U.S.Pat. No. 5,705,624 to Fitzmaurice et al.; U.S. Pat. No. 5,844,119 toWeigl; U.S. Pat. No. 6,730,832 to Dominguez et al.; U.S. Pat. No.7,173,170 to Liu et al.; U.S. Pat. No. 7,208,659 to Colliver et al. andU.S. Pat. No. 7,230,160 to Benning et al.; U.S. Pat. Appl. Pub. No.2006/0236434 to Conkling et al.; and PCT WO 2008/103935 to Nielsen etal.

For the preparation of smokeless and smokable tobacco products, it istypical for a harvested plant of the Nicotiana species to be subjectedto a curing process. Descriptions of various types of curing processesfor various types of tobaccos are set forth in Tobacco Production,Chemistry and Technology, Davis et al. (Eds.) (1999). Exemplarytechniques and conditions for curing flue-cured tobacco are set forth inNestor et al., Beitrage Tabakforsch. Int., 20, 467-475 (2003) and U.S.Pat. No. 6,895,974 to Peele, which are incorporated herein by reference.Representative techniques and conditions for air curing tobacco are setforth in U.S. Pat. No. 7,650,892 to Groves et al.; Roton et al.,Beitrage Tabakforsch. Int., 21, 305-320 (2005) and Staaf et al.,Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporatedherein by reference. Certain types of tobaccos can be subjected toalternative types of curing processes, such as fire curing or suncuring. Preferably, harvested tobaccos that are cured are then aged. Assuch, tobaccos used for the preparation of tobacco compositions orproducts most preferably incorporate components of tobaccos that havebeen cured and aged. Tobacco materials used in the present invention canbe subjected to additional processing prior to use, such asfermentation, bleaching, and the like.

At least a portion of the plant of the Nicotiana species (e.g., at leasta portion of the tobacco portion) can be employed in an immature form.That is, the plant, or at least one portion of that plant, can beharvested before reaching a stage normally regarded as ripe or mature.As such, for example, tobacco can be harvested when the tobacco plant isat the point of a sprout, is commencing leaf formation, is commencingflowering, or the like.

At least a portion of the plant of the Nicotiana species (e.g., at leasta portion of the tobacco portion) can be employed in a mature form. Thatis, the plant, or at least one portion of that plant, can be harvestedwhen that plant (or plant portion) reaches a point that is traditionallyviewed as being ripe, over-ripe or mature. As such, for example, throughthe use of tobacco harvesting techniques conventionally employed byfarmers, Oriental tobacco plants can be harvested, burley tobacco plantscan be harvested, or Virginia tobacco leaves can be harvested or primedby stalk position.

After harvest, the plant of the Nicotiana species, or portion thereof,can be used in a green form (e.g., tobacco can be used without beingsubjected to any curing process). For example, tobacco in green form canbe frozen, subjected to irradiation, yellowed, dried, cooked (e.g.,roasted, fried or boiled), or otherwise subjected to storage ortreatment for later use. Such tobacco also can be subjected to agingconditions.

The tobacco material may be cased and dried, and then ground to thedesired form. For example, in some instances, the tobacco materialformulation may be cased with an aqueous casing containing componentssuch as sugars (e.g., fructose, glucose, and sucrose), humectants (e.g.,glycerin and propylene glycol), flavoring ingredients (e.g., cocoa andlicorice), and the like. Non-aqueous casing components may be applied tothe tobacco in amounts of about 1 percent to about 15 percent, based onthe dry weight of the tobacco.

At least a portion of the tobacco material employed in the tobaccocomposition or product can have the form of an extract. Tobacco extractscan be obtained by extracting tobacco using a solvent having an aqueouscharacter such as distilled water or tap water. As such, aqueous tobaccoextracts can be provided by extracting tobacco with water, such thatwater insoluble pulp material is separated from the aqueous solvent andthe water soluble and dispersible tobacco components dissolved anddispersed therein. The tobacco extract can be employed in a variety offorms. For example, the aqueous tobacco extract can be isolated in anessentially solvent free form, such as can be obtained as a result ofthe use of a spray drying or freeze drying process, or other similartypes of processing steps. Alternatively, the aqueous tobacco extractcan be employed in a liquid form, and as such, the content of tobaccosolubles within the liquid solvent can be controlled by selection of theamount of solvent employed for extraction, concentration of the liquidtobacco extract by removal of solvent, addition of solvent to dilute theliquid tobacco extract, or the like. Exemplary techniques for extractingcomponents of tobacco are described in U.S. Pat. No. 4,144,895 to Fiore;U.S. Pat. No. 4,150,677 to Osborne, Jr. et al.; U. S. Pat. No. 4,267,847to Reid; U.S. Pat. No. 4,289,147 to Wildman et al.; U.S. Pat. No.4,351,346 to Brummer et al.; U.S. Pat. No. 4,359,059 to Brummer et al.;U.S. Pat. No. 4,506,682 to Muller; U.S. Pat. No. 4,589,428 to Keritsis;U.S. Pat. No. 4,605,016 to Soga et al.; U.S. Pat. No. 4,716,911 toPoulose et al.; U.S. Pat. No. 4,727,889 to Niven, Jr. et al.; U.S. Pat.No. 4,887,618 to Bernasek et al.; U.S. Pat. No. 4,941,484 to Clapp etal.; U.S. Pat. No. 4,967,771 to Fagg et al.; U.S. Pat. No. 4,986,286 toRoberts et al.; U.S. Pat. No. 5,005,593 to Fagg et al.; U.S. Pat. No.5,018,540 to Grubbs et al.; U.S. Pat. No. 5,060,669 to White et al.;U.S. Pat. No. 5,065,775 to Fagg; U.S. Pat. No. 5,074,319 to White etal.; U.S. Pat. No. 5,099,862 to White et al.; U.S. Pat. No. 5,121,757 toWhite et al.; U.S. Pat. No. 5,131,414 to Fagg; U.S. Pat. No. 5,131,415to Munoz et al.; U.S. Pat. No. 5,148,819 to Fagg; U.S. Pat. No.5,197,494 to Kramer; U.S. Pat. No. 5,230,354 to Smith et al.; U.S. Pat.No. 5,234,008 to Fagg; U.S. Pat. No. 5,243,999 to Smith; U.S. Pat. No.5,301,694 to Raymond et al.; U.S. Pat. No. 5,318,050 to Gonzalez-Parraet al.; U.S. Pat. No. 5,343,879 to Teague; US. Pat. No. 5,360,022 toNewton; U.S. Pat. No. 5,435,325 to Clapp et al.; U.S. Pat. No. 5,445,169to Brinkley et al.; U.S. Pat. No. 6,131,584 to Lauterbach; U.S. Pat. No.6,284,875 to Turpen et al.; U.S. Pat. No. 6,298,859 to Kierulff et al.;U.S. Pat. No. 6,772,767 to Mua et al.; U.S. Pat. No. 6,817,970 to Beritet al.; U.S. Pat. No. 6,906,172 to Bratcher et al.; U.S. Pat. No.7,034,128 to Turpen et al.; U.S. Pat. No. 7,048,211 to Bratcher et al.;and U.S. Pat. No. 7,337,782 to Thompson, all of which are incorporatedby reference herein.

The tobacco material is typically used in a form that can be describedas particulate (i.e., shredded, ground, granulated, or powder form). Themanner by which the tobacco material is provided in a finely divided orpowder type of form may vary. Preferably, plant parts or pieces arecomminuted, ground or pulverized into a particulate form using equipmentand techniques for grinding, milling, or the like. Most preferably, theplant material is relatively dry in form during grinding or milling,using equipment such as hammer mills, cutter heads, air control mills,or the like. For example, tobacco parts or pieces may be ground ormilled when the moisture content thereof is less than about 15 weightpercent or less than about 5 weight percent. Most preferably, thetobacco material is employed in the form of parts or pieces that have anaverage particle size less than about 50 microns. In one embodiment, theaverage particle size of the tobacco particles may be less than or equalto about 25 microns. In some instances, the tobacco particles may besized to pass through a screen mesh. If desired, air classificationequipment may be used to ensure that small sized tobacco particles ofthe desired sizes, or range of sizes, may be collected. If desired,differently sized pieces of granulated tobacco may be mixed together.

The relative amount of tobacco material within the smokeless tobaccocomposition may vary, but tobacco material is typically the predominateingredient. Preferably, the amount of tobacco material formulationwithin the smokeless tobacco composition is at least about 25 percent orat least about 30 percent, on a dry weight basis of the composition. Incertain instances, the amounts of other components within the smokelesstobacco composition may exceed about 40 percent, on a dry weight basis.A typical range of tobacco material formulation within the smokelesstobacco composition is about 25 to about 60 dry weight percent, moretypically about 30 to about 40 dry weight percent.

In certain embodiments, the tobacco material may not be the predominateingredient, wherein the tobacco material may be in the form of a tobaccoextract having a liquid form, spray-dried form, or dehydrated form. Atypical range for this type of tobacco material within the smokelesstobacco composition is about 5 to about 40 dry weight percent, about 5to about 25 dry weight percent, about 10 to about 30 dry weight percent,or about 20 to about 40 dry weight percent.

The moisture content of the tobacco material formulation prior to mixingwith any liquid substances to form the smokeless tobacco composition mayvary. Most preferably, the moisture content of the tobacco materialformulation is less than about 10 weight percent, and may be less thanabout 5 percent, and is often less than about 2.5 weight percent. Themanner by which the moisture content of the tobacco material formulationis controlled may vary. For example the tobacco material formulation maybe subjected to thermal or convection heating. As a specific example,the tobacco material formulation may be oven-dried, in warmed air attemperatures of about 40° C. to about 95° C. for a length of timeappropriate to attain the desired moisture content. For example, thetobacco material formulation may be dried for about 12 hours to about 24hours at about 54° C. to about 60° C.

In some instances, prior to preparation of the tobacco materialformulation, the tobacco parts or pieces may be irradiated, or thoseparts and pieces may be pasteurized, or otherwise subjected tocontrolled heat treatment. Additionally, if desired, after preparationof all or a portion of the tobacco material formulation, the componentmaterials may be irradiated, or those component materials may bepasteurized, or otherwise subjected to controlled heat treatment. Forexample, a tobacco material formulation may be prepared, followed byirradiation or pasteurization, and then flavoring ingredient(s) may beapplied to the formulation. Representative processes are set forth inU.S. Pat. Pub. No. 2009/0025738 to Mua et al. and U.S. Pat. Pub. No.2009/0025739 to Brinkley et al.; and U.S. application Ser. No.12/756,656 to Beeson et al., filed Apr. 8, 2010, which are incorporatedherein by reference.

The tobacco material formulation used for the manufacture of thesmokeless tobacco product also can be processed, blended, formulated,combined and mixed with other materials or ingredients (i.e.,additives). See, for example, those representative components,combination of components, relative amounts of those components andingredients relative to tobacco, and manners and methods for employingthose components, set forth in U.S. Pat. Pub. No. 2007/0062549 toHolton, et al. and U.S. Pat. Pub. No. 2007/0186941 to Holton, et al.,each of which is incorporated herein by reference.

The additives can be artificial, or can be obtained or derived fromherbal or biological sources. Exemplary types of additives include salts(e.g., sodium chloride, potassium chloride, sodium citrate, potassiumcitrate, sodium acetate, potassium acetate, and the like), naturalsweeteners (e.g., fructose, sucrose, glucose, maltose, vanillin,ethylvanillin glucoside, mannose, galactose, lactose, and the like),artificial sweeteners (e.g., sucralose, saccharin, aspartame, acesulfameK, neotame and the like), organic and inorganic fillers (e.g., grains,processed grains, puffed grains, maltodextrin, dextrose, calciumcarbonate, calcium phosphate, corn starch, lactose, sugar alcohols suchas isomalt, mannitol, xylitol, or sorbitol, finely divided cellulose,vegetable protein, and the like), binders (e.g., povidone, sodiumcarboxymethylcellulose and other modified cellulosic types of binders,sodium alginate, xanthan gum, starch-based binders, gum arabic, gellangum, lecithin, and the like), gelling agents (e.g., fish gelatin), pHadjusters or buffering agents (e.g., metal hydroxides, preferably alkalimetal hydroxides such as sodium hydroxide and potassium hydroxide, andother alkali metal buffers such as metal carbonates, preferablypotassium carbonate or sodium carbonate, or metal bicarbonates such assodium bicarbonate, and the like), emulsifiers, colorants (e.g., dyesand pigments, including caramel coloring, titanium dioxide, and thelike), humectants (e.g., glycerin, propylene glycol, and the like), oralcare additives (e.g., thyme oil, eucalyptus oil, and zinc),preservatives (e.g., potassium sorbate and the like), syrups (e.g.,honey, high fructose corn syrup, and the like), disintegration orcompressibility aids (e.g., microcrystalline cellulose, croscarmellosesodium, crospovidone, sodium starch glycolate, pregelatinized cornstarch, and the like), flavorant and flavoring mixtures, antioxidants,and mixtures thereof. Exemplary types of additives may include thosedescribed in, for example, U.S. Pat. Pub. No. 2010/0291245 to Gao etal., previously incorporated by reference herein.

Such additives may be provided in a powder or granulated form for mixingwith the tobacco material formulation, or otherwise may be provided inliquid form. Most preferably, the additive when provided in a powder orgranulated form is employed in the form of parts or pieces that have anaverage particle size less than about 50 microns. According to someaspects, the average particle size of the additive may be about 25microns or less. The moisture content of the additives provided in apowder or granulated form may vary. Most preferably, the moisturecontent of the additive provided in a powder or granulated form is lessthan about 10 weight percent, and may be less than about 5 percent, andis often less than about 2.5 weight percent. The additive may be admixedwith the particulate tobacco material in, for example, a Hobart mixerwith a paddle prior to adding any liquid additives. In the event liquidadditives are provided, the resultant mixture may still have arelatively low moisture content of less than about 10 weight percent,and may be less than about 5 percent, and is often less than about 2.5weight percent. The relative amounts of the various additive componentswithin the smokeless tobacco product may vary.

The aforementioned types of additives can be employed together (e.g., asadditive formulations) or separately (e.g., individual additivecomponents can be added at different stages involved in the preparationof the final tobacco product). The relative amounts of the variouscomponents within the smokeless tobacco formulation may vary, andtypically are selected so as to provide the desired sensory andperformance characteristics to the tobacco product. Furthermore, theaforementioned types of additives may be encapsulated as provided in thefinal product or composition. Exemplary encapsulated additives aredescribed, for example, in WO 2010/132444 A2 to Atchley, which has beenpreviously incorporated by reference herein.

Any of the above-noted classes of additives for the smokeless tobaccocomposition of the invention can be derived from tobacco material bysubjecting at least a portion of a tobacco plant (e.g., leaves, seeds,flowers, stalks, roots, or stems) to a separation process, whichtypically can include multiple sequential extraction steps, in order toisolate desired components of the tobacco material. Exemplary separationprocesses include chromatography, distillation, filtration,recrystallization, solvent-solvent partitioning, cold pressing, solventextraction (e.g., using solvents such as water, alcohols or hydrocarbonssuch as heptane or hexane), or a combination thereof. The resultingisolated tobacco component can be chemically transformed prior to use inthe compositions of the invention. Exemplary chemical transformationsinclude hydrogenation, esterification, transesterification, isomericconversion, acetal formation, acetal decomposition, acid/base reaction,hydrolysis, thermal treatment, enzymatic treatment, and combinations ofsuch steps. Techniques for preparing tobacco isolates for use in thecompositions of the invention are set forth, for example, in U.S.application Ser. No. 12/688,294 to Coleman, III et al., filed Jan. 15,2010, and U.S. application Ser. No. 12/764,613 to Coleman, III et al.,filed Apr. 21, 2010, which are incorporated by reference herein in theirentirety. Examples of the types of compounds that may be present in thetobacco isolate include hydrocarbons, cellulose, alcohols, aldehydes,ketones, carboxylic acids, amino acids, esters, lactones, anhydrides,carbohydrates (e.g., reducing sugars), phenols, quinones, ethers,nitriles, amines, amides, imides, plastid pigments, proteins,coenzyme-Q, pectin, starch, lignin, and lipids. Additional examples aredescribed as natural tar diluents in PCT WO 2007/012980 to Lipowicz,which is incorporated by reference herein in its entirety. The type orfunction of a smokeless tobacco additive prepared from a tobacco isolatewill vary depending on the composition of the isolate, which can vary inpart based on the extraction process employed, the portion of thetobacco plant involved, the type of chemical transformation utilized,and the like. Certain tobacco isolates can provide sugars, fillers,binders, disintegration or compressibility aids, or flavorants for thesmokeless tobacco composition of the invention.

As used herein, a “flavorant” or “flavoring agent” is any flavorful oraromatic substance capable of altering the sensory characteristicsassociated with the smokeless tobacco composition. Exemplary sensorycharacteristics that can be modified by the flavorant include, taste,mouthfeel, moistness, coolness/heat, and/or fragrance/aroma. Theflavorants can be natural or synthetic, and the character of theseflavors can be described as, without limitation, fresh, sweet, herbal,confectionary, floral, fruity or spice. Specific types of flavorsinclude, but are not limited to, vanilla, coffee, chocolate, cream,mint, spearmint, menthol, peppermint, wintergreen, lavender, cardamon,nutmeg, cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger,anise, sage, licorice, lemon, orange, apple, peach, lime, cherry, andstrawberry. Flavorants utilized in the invention also can includecomponents that are considered moistening, cooling or smootheningagents, such as eucalyptus. These flavors may be provided neat (i.e.,alone) or in a composite (e.g., spearmint and menthol or orange andcinnamon). In some instances, the flavorant may be provided in aspray-dried form. Flavorants are typically present in an amount of about0.5 to about 10 dry weight percent, often about 1 to about 6 dry weightpercent, and most often about 2 to about 5 dry weight percent.

Sweeteners can be used in natural or artificial form or as a combinationof artificial and natural sweeteners. In one embodiment, sucralose is aprimary sweetener ingredient. When present, a representative amount ofsweetener, whether an artificial sweetener and/or natural sugar, maymake up at least about 0.2 percent or at least about 5 percent, of thetotal dry weight of the composition. Preferably, the amount of sweetenerwithin the composition will not exceed about 40 percent, often will notexceed about 35 percent, and frequently will not exceed about 30percent, of the total dry weight of the composition.

A syrup preferably may be employed in amounts sufficient to providedesired flavor attributes to the smokeless tobacco composition. Whenpresent, a representative amount of syrup (e.g., high fructose cornsyrup) may make up less than about 5 percent of the total dry weight ofthe composition.

The smokeless tobacco compositions of the disclosure may typicallyinclude at least one filler ingredient in addition to the polysaccharidefiller component. Such components of the composition often fulfillmultiple functions, such as enhancing certain organoleptic propertiessuch as texture and mouthfeel, enhancing cohesiveness or compressibilityof the product, and the like. When present, a representative amount ofadditional filler, whether an organic and/or inorganic filler, may makeup at least about 10 percent, at least about 20 percent, or at leastabout 25 percent, based on the total dry weight of the composition.Preferably, the amount of additional filler within the composition willnot exceed about 50 percent, and frequently will not exceed about 40percent, of the total dry weight of the composition. In one embodiment,a sugar alcohol such as sorbitol is provided as an additional filler.

A salt (e.g., sodium chloride) may be employed in amounts sufficient toprovide desired sensory attributes to the smokeless tobacco composition.When present, a representative amount of salt will typically make upless than about 2 percent of the total dry weight of the composition.

A humectant (e.g., glycerin) may be employed in amounts sufficient toprovide desired moisture attributes to the smokeless tobaccocomposition. When present, a representative amount of humectant willtypically make up at least about 1 percent of the total dry weight ofthe composition, and often at least about 2 percent by weight. Incertain embodiments, the amount of humectants is at least about 10 dryweight percent or at least about 20 dry weight percent. An exemplary dryweight range is about 1 to about 40 weight percent, more often about 3to about 35 dry weight percent.

A binder may be employed in amounts sufficient to provide the desiredphysical attributes and physical integrity to the smokeless tobaccocomposition. When present, a representative amount of binder may make upat least about 5 percent or at least about 10 percent of the total dryweight of the composition. Preferably, the amount of binder within thecomposition will not exceed about 35 percent of the total dry weight ofthe composition. Often, the amount of binder within a desirablecomposition will not exceed about 20 percent, and frequently will notexceed about 15 percent, of the total dry weight of the composition.Representative binders include various natural gums, which are typicallywater soluble to some degree, such as xanthan gum, guar gum, gum arabic,ghatti gum, gum tragacanth, karaya gum, locust bean gum, gellan gum, andcombinations thereof.

An emulsifier may be employed in amounts sufficient to provide desiredstabilization attributes to the smokeless tobacco composition. Whenpresent, a representative amount of emulsifier will typically make upless than about 5 percent of the total dry weight of the composition.

Representative smokeless tobacco compositions may incorporate about 25to about 35 percent tobacco, about 10 to about 20 percent polysaccharidefiller component (e.g., polydextrose), about 0 to about 1 percentartificial sweetener, about 25 to about 35 percent humectant, about 1 toabout 2 percent emulsifier, about 3 to about 5 percent syrup, about 10to about 20 percent binder, flavoring ingredient in an amount of up toabout 1 percent, and salt in an amount up to about 2 percent, based onthe total dry weight of the smokeless tobacco composition. Theparticular percentages and choice of ingredients will vary dependingupon the desired flavor, texture, and other characteristics.

The manner by which the various components of the smokeless tobaccocomposition are combined may vary. The various components of thesmokeless tobacco composition may be contacted, combined, or mixedtogether in conical-type blenders, mixing drums, ribbon blenders, or thelike, such as a Hobart mixer. As such, the overall mixture of variouscomponents with the powdered tobacco components may be relativelyuniform in nature. See also, for example, the types of methodologies setforth in U.S. Pat. No. 4,148,325 to Solomon et al.; U.S. Pat. No.6,510,855 to Korte et al.; and U.S. Pat. No. 6,834,654 to Williams, eachof which is incorporated herein by reference.

The ingredients forming the dissolvable smokeless tobacco compositionare prepared such that the mixture thereof may be used in an injectionmolding process for forming the smokeless tobacco product. In oneaspect, all dry ingredients, including the particulate tobacco materialand binder, are admixed. In this regard, at least the particulatetobacco material, polysaccharide filler component, and binder may beplaced in a mixing vessel (e.g., Hobart mixer—Model N-50) for mixing.After mixing the dry ingredients, a liquid mixture may be added to thedry mix. That is, in some instances, some ingredients (e.g., syrups,humectants, emulsifiers) may be heated to form a liquid melt solution.The resultant mixture of dry and liquid ingredients may then be passedthrough a grinder apparatus (e.g., meat grinder on the Hobartmixer—Model M802) so as to force the liquid ingredients into the dryingredients via an extrusion process, which forms a paste-likesubstance. The extruded substance may then be placed into a small Hobartmixer and mixed so as to form a powder granulation.

After preparing the smokeless tobacco composition, an injection moldingprocedure may be used to form the smokeless tobacco pastille product. Inthis regard, an injection molding apparatus may be used to exertcompressive forces on the smokeless tobacco composition. As used herein,the term “injection-molded” refers to a product formed by injecting orotherwise forcing a liquid, semi-liquid, or granulation composition intoa mold or other forming device(s), with application of compressive forceapplied to the injected composition. The smokeless tobacco compositionto be injection molded will typically have a moisture content of lessthan about 5 percent by weight, and often less than about 2.5 percent byweight. The smokeless tobacco composition is transferred to a mold,which in some instances may be a steel block in two discrete pieces. Insome instances, a so-called “one-up” mold may be used, wherein a moldblock comprises two halves of steel with a cored out shape. The interiorformed by the mold is shaped to provide a desired configurationassociated with the final pastille product. In some instances, the moldblock may be heated to an elevated temperature such as, for example, toabout 50° C. to about 100° C., and preferably to about 60° C. Thesmokeless tobacco composition is poured into the mold block and then acompressive pressure is applied to the smokeless tobacco compositionusing, for example, a hydraulic press unit (e.g., Wabach HydraulicPress, Model 12-102T, Serial 2201). According to one aspect, acompressive force of at least about 75,000 kPa, and preferably at leastabout 100,000 kPa, is applied to the smokeless tobacco composition,although the amount of compressive force applied may vary. For example,a compressive force of at least about 30,000 kPa to about 120,000 kPamay be applied.

The amount of time the smokeless tobacco composition is compressed mayvary. For example, the smokeless tobacco composition may be compressedfor about 1 minute to about 5 minutes. After applying the compressiveforce, the smokeless tobacco composition may be removed from theinjection mold after cooling the mold block to about 30° C. to about 40°C. The smokeless tobacco composition may then be allowed to cool atambient temperature or at about 20° C. to about 25° C. The resultantpastille product may be provided in individual pieces weighing betweenabout 4 grams to about 15 grams, although aspects of the presentdisclosure are not limited to such weights. It is noted, however, thatexact injection molded formulations may depend upon equipment used,desired characteristics of the final product, amount of heat/pressureapplied, etc.

The dissolvable smokeless tobacco pastille product can be provided inany suitable predetermined shape or form, and most preferably isprovided in the form having a general shape of a pill, pellet, tablet,coin, bead, ovoid, obloid, cube, or the like. The mouthfeel of thesmokeless tobacco product is preferably a slightly chewable anddissolvable quality. According to one aspect, the dissolvable smokelesstobacco pastille product is preferably capable of lasting in the user'smouth for about 10-15 minutes until it completely dissolves. Preferably,the pastille products do not, to any substantial degree, leave anyresidue in the mouth of the user thereof, and do not impart a slick,waxy, or slimy sensation to the mouth of the user.

According to some aspects, the tobacco particulate component of thepastille composition may be replaced with other suitable botanicalparticulate components such as, for example, tea particulates, coffeeparticulates, herbal particulates, spice particulates and/orcombinations thereof. The particulates may be typically provided in apowder form, which may be extracted from an appropriate botanicalsource.

Products of the present invention may be packaged and stored in anysuitable packaging. See, for example, the various types of containersfor smokeless types of products that are set forth in U.S. Pat. No.7,014,039 to Henson et al.; U.S. Pat. No. 7,537,110 to Kutsch et al.;U.S. Pat. No. 7,584,843 to Kutsch et al.; D592,956 to Thiellier andD594,154 to Patel et al.; U.S. Pat. Pub. No. 2008/0173317 to Robinson etal.; U.S. Pat. Pub. No. 2009/0014343 to Clark et al.; U.S. Pat. Pub. No.2009/0014450 to Bjorkholm; U.S. Pat. Pub. No. 2009/0250360 to Bellamahet al.; U.S. Pat. Pub. No. 2009/0266837 to Gelardi et al.; U.S. Pat.Pub. No. 2009/0223989 to Gelardi; U.S. Pat. Pub. No. 2009/0230003 toThiellier; U.S. Pat. Pub. No. 2010/0084424 to Gelardi; and U.S. Pat.Pub. No. 2010/0133140 to Bailey et al; and U.S. patent application Ser.No. 29/342,212, filed Aug. 20, 2009, to Bailey et al.; U.S. patentapplication Ser. No. 12/425,180, filed Apr. 16, 2009, to Bailey et al.;U.S. patent application Ser. No. 12/685,819, filed Jan. 12, 2010, toBailey et al.; and U.S. patent application Ser. No. 12/814,015, filedJun. 11, 2010, to Gelardi et al., which are incorporated herein byreference.

EXPERIMENTAL

The following examples are provided to illustrate further aspectsassociated with the present invention, but should not be construed aslimiting the scope thereof. Unless otherwise noted, all parts andpercentages are by dry weight.

Example 1

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A 70% sugar solution is prepared. The sugar solution is admixed andheated with corn syrup, glycerin, and a flavorant to form a liquidblend.

A tobacco material having an average particle size of less than about100 microns is mixed with a salt, sucralose, and a binder material (gumarabic) in a Hobart mixing bowl. The liquid blend is added to the Hobartmixing bowl containing the tobacco and binder material, wherein theingredients are admixed in a Hobart mixer (Model N-50) for about 4-5minutes at about 120 rpm to form a smokeless tobacco composition. Thesmokeless tobacco composition is extruded through a grinder apparatus.Upon extrusion, the smokeless tobacco composition is placed in a Hobartmixer to form a powder granulation. The mixture of the smokeless tobaccocomposition is about 28 parts binder material, 30.7 parts tobaccomaterial, 32.7 parts sugar solution, 3.5 parts corn syrup, 2.1 partsglycerin, 1.8 parts salt, 0.2 parts sucralose, and 1 part flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 2

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A 70% sugar solution is prepared. The sugar solution is admixed andheated with an emulsifier (available as DUR-EM 117 from LodersCroklaan), corn syrup, glycerin, and a flavorant to form a liquid blend.

A tobacco material having an average particle size of less than about100 microns is mixed with salt, sucralose, and a binder material (gumarabic) in a Hobart mixing bowl. The liquid blend is added to the Hobartmixing bowl containing the tobacco and binder material, wherein theingredients are admixed in Hobart mixer (Model N-50) for about 4-5minutes at about 120 rpm to form a smokeless tobacco composition. Thesmokeless tobacco composition is extruded through a grinder apparatus.Upon extrusion, the smokeless tobacco composition is placed in a Hobartmixer to form a powder granulation. The mixture of the smokeless tobaccocomposition is about 28 parts binder material, 30.7 parts tobaccomaterial, 0.5 parts emulsifier, 32.1 parts sugar solution, 3.5 partscorn syrup, 2.1 parts glycerin, 1.8 parts salt, 0.2 parts sucralose, and1 part flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 3

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (sorbitol), an emulsifier (available as DUR-EM 117 from LodersCroklaan), corn syrup, glycerin and a flavorant are admixed and heatedto form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose and a binder material (gum arabic) in a Hobart mixing bowl.The liquid blend is added to the Hobart mixing bowl containing thetobacco material blend and the binder material, wherein the ingredientsare admixed in Hobart mixer (Model N-50) for about 4-5 minutes at about120 rpm to form a smokeless tobacco composition. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 28 parts binder material, 30.6 parts tobacco material, 28 partsfiller, 5 parts emulsifier, 3.5 parts corn syrup, 2.1 parts glycerin,1.8 parts salt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 4

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose and a binder material (gum arabic) in a Hobart mixing bowl.The liquid blend is added to the Hobart mixing bowl containing thetobacco material blend and the binder material, wherein the ingredientsare admixed in Hobart mixer (Model N-50) for about 4-5 minutes at about120 rpm to form a smokeless tobacco composition. The smokeless tobaccocomposition is passed through a meat grinder on the Hobart mixer toincorporate the liquid ingredients into the dry ingredients. Thesmokeless tobacco composition is extruded through a grinder apparatus.Upon extrusion, the smokeless tobacco composition is placed in a Hobartmixer to form a powder granulation. The mixture of the smokeless tobaccocomposition is about 27.2 parts binder material, 29.6 parts tobaccomaterial, 27.2 parts filler, 7.8 parts emulsifier, 3.4 parts corn syrup,2 parts glycerin, 1.7 parts salt, 0.2 parts sucralose, and 0.8 partsflavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 5

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose and a binder material (xanthan gum) in a Hobart mixing bowl.The liquid blend is added to the Hobart mixing bowl containing thetobacco material blend and the binder material, wherein the ingredientsare admixed in Hobart mixer (Model N-50) for about 4-5 minutes at about120 rpm to form a smokeless tobacco composition. The smokeless tobaccocomposition is passed through a meat grinder on the Hobart mixer toincorporate the liquid ingredients into the dry ingredients. Thesmokeless tobacco composition is extruded through a grinder apparatus.Upon extrusion, the smokeless tobacco composition is placed in a Hobartmixer to form a powder granulation. The mixture of the smokeless tobaccocomposition is about 27.2 parts binder material, 29.6 parts tobaccomaterial, 27.2 parts filler, 7.8 parts emulsifier, 3.4 parts corn syrup,2 parts glycerin, 1.7 parts salt, 0.2 parts sucralose, and 0.8 partsflavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 6

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose and a binder material (available as NYMCEL ZSX-W from CPKelco) in a Hobart mixing bowl. The liquid blend is added to the Hobartmixing bowl containing the tobacco material blend and the bindermaterial, wherein the ingredients are admixed in Hobart mixer (ModelN-50) for about 4-5 minutes at about 120 rpm to form a smokeless tobaccocomposition. The smokeless tobacco composition is passed through a meatgrinder on the Hobart mixer to incorporate the liquid ingredients intothe dry ingredients. The smokeless tobacco composition is extrudedthrough a grinder apparatus. Upon extrusion, the smokeless tobaccocomposition is placed in a Hobart mixer to form a powder granulation.The mixture of the smokeless tobacco composition is about 27.2 partsbinder material, 29.6 parts tobacco material, 27.2 parts filler, 7.8parts emulsifier, 3.4 parts corn syrup, 2 parts glycerin, 1.7 partssalt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 7

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose and a binder material (gellan gum) in a Hobart mixing bowl.The liquid blend is added to the Hobart mixing bowl containing thetobacco material blend and the binder material, wherein the ingredientsare admixed in Hobart mixer (Model N-50) for about 4-5 minutes at about120 rpm to form a smokeless tobacco composition. The smokeless tobaccocomposition is passed through a meat grinder on the Hobart mixer toincorporate the liquid ingredients into the dry ingredients. Thesmokeless tobacco composition is extruded through a grinder apparatus.Upon extrusion, the smokeless tobacco composition is placed in a Hobartmixer to form a powder granulation. The mixture of the smokeless tobaccocomposition is about 27.2 parts binder material, 29.6 parts tobaccomaterial, 27.2 parts filler, 7.8 parts emulsifier, 3.4 parts corn syrup,2 parts glycerin, 1.7 parts salt, 0.2 parts sucralose, and 0.8 partsflavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 8

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose and a binder material (gum arabic) in a Hobart mixing bowl.The liquid blend is added to the Hobart mixing bowl containing thetobacco material blend and the binder material, wherein the ingredientsare admixed in Hobart mixer (Model N-50) for about 4-5 minutes at about120 rpm to form a smokeless tobacco composition. The smokeless tobaccocomposition is passed through a meat grinder on the Hobart mixer toincorporate the liquid ingredients into the dry ingredients. Thesmokeless tobacco composition is extruded through a grinder apparatus.Upon extrusion, the smokeless tobacco composition is placed in a Hobartmixer to form a powder granulation. The mixture of the smokeless tobaccocomposition is about 29.2 parts binder material, 31.8 parts tobaccomaterial, 29.2 parts filler, 1 part emulsifier, 3.6 parts corn syrup,2.2 parts glycerin, 1.9 parts salt, 0.2 parts sucralose, and 0.8 partsflavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 9

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A humectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), cornsyrup, glycerin and a flavorant are admixed and heated to form a liquidblend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose, a binder material (gum arabic) and polydextrose powder(available as LITESSE from Danisco A/S) in a Hobart mixing bowl. Theliquid blend is added to the Hobart mixing bowl containing the tobaccomaterial blend, binder material, and polydextrose powder, wherein theingredients are admixed in Hobart mixer (Model N-50) for about 4-5minutes at about 120 rpm to form a smokeless tobacco composition. Thesmokeless tobacco composition is passed through a meat grinder on theHobart mixer to incorporate the liquid ingredients into the dryingredients. The smokeless tobacco composition is extruded through agrinder apparatus. Upon extrusion, the smokeless tobacco composition isplaced in a Hobart mixer to form a powder granulation. The mixture ofthe smokeless tobacco composition is about 14.6 parts binder material,31.8 parts tobacco material, 29.2 parts humectant, 1 part emulsifier,14.6 parts polydextrose, 3.6 parts corn syrup, 2.2 parts glycerin, 1.9parts salt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 10

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose, a binder material (gum arabic) and a polysaccharide(maltodextrin; available as MALTRIN M100 from Grain ProcessingCorporation) in a Hobart mixing bowl. The liquid blend is added to theHobart mixing bowl containing the tobacco material blend, bindermaterial, and polysaccharide, wherein the ingredients are admixed inHobart mixer (Model N-50) for about 4-5 minutes at about 120 rpm to forma smokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 14.6 parts binder material, 31.8 parts tobacco material, 14.6parts polysaccharide, 29.2 parts filler, 1 part emulsifier, 3.6 partscorn syrup, 2.2 parts glycerin, 1.9 parts salt, 0.2 parts sucralose, and0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 11

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A filler (maltitol; available as LYCASIN from Roquette Freres S.A.), anemulsifier (available as DUR-EM 117 from Loders Croklaan), corn syrup,glycerin and a flavorant are admixed and heated to form a liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose, a binder material (gum arabic) and a polysaccharide (pullulanpowder) in a Hobart mixing bowl. The liquid blend is added to the Hobartmixing bowl containing the tobacco material blend, binder material, andpolysaccharide, wherein the ingredients are admixed in Hobart mixer(Model N-50) for about 4-5 minutes at about 120 rpm to form a smokelesstobacco composition. The smokeless tobacco composition is passed througha meat grinder on the Hobart mixer to incorporate the liquid ingredientsinto the dry ingredients. The smokeless tobacco composition is extrudedthrough a grinder apparatus. Upon extrusion, the smokeless tobaccocomposition is placed in a Hobart mixer to form a powder granulation.The mixture of the smokeless tobacco composition is about 14.6 partsbinder material, 31.8 parts tobacco material, 14.6 parts polysaccharide,29.2 parts filler, 1 part emulsifier, 3.6 parts corn syrup, 2.2 partsglycerin, 1.9 parts salt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 12

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A humectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), cornsyrup, glycerin and a flavorant are admixed and heated to form a liquidblend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with salt,sucralose, a binder material (gum arabic) and polydextrose powder(available as LITESSE from Danisco A/S) in a Hobart mixing bowl. Theliquid blend is added to the Hobart mixing bowl containing the tobaccomaterial blend, binder material, and polydextrose powder, wherein theingredients are admixed in Hobart mixer (Model N-50) for about 4-5minutes at about 120 rpm to form a smokeless tobacco composition. Thesmokeless tobacco composition is passed through a meat grinder on theHobart mixer to incorporate the liquid ingredients into the dryingredients. The smokeless tobacco composition is extruded through agrinder apparatus. Upon extrusion, the smokeless tobacco composition isplaced in a Hobart mixer to form a powder granulation. The mixture ofthe smokeless tobacco composition is about 15.1 parts binder material,32.9 parts tobacco material, 26.9 parts humectant, 1.1 parts emulsifier,15.1 parts polydextrose, 3.8 parts corn syrup, 2.3 parts glycerin, 1.9parts salt, 0.2 parts sucralose, and 0.9 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 13

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A humectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), avegetable protein (available from Freeman Industries LLC), corn syrup,and glycerin are admixed to form a liquid blend. The liquid blend isheated to about 54° C. A flavorant is added to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 11.1 parts binder material, 31.8 parts tobacco material, 29.2parts humectant, 1 part emulsifier, 3.5 parts vegetable protein, 14.6parts polydextrose, 3.6 parts corn syrup, 2.2 parts glycerin, 1.9 partssalt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 14

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A vegetable protein (available from Freeman Industries LLC) is combinedwith water. A humectant (available as HYSTAR 3375 from Corn ProductsInternational), an emulsifier (available as DUR-EM 117 from LodersCroklaan), corn syrup, glycerin and the hydrated vegetable protein areadmixed to form a liquid blend. The liquid blend is heated to about 54°C. A flavorant is added to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 9.9 parts binder material, 28.4 parts tobacco material, 26 partshumectant, 0.9 parts emulsifier, 3.3 parts vegetable protein, 10.6 partswater, 13 parts polydextrose, 3.3 parts corn syrup, 2 parts glycerin,1.7 parts salt, 0.2 parts sucralose, and 0.7 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 15

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A humectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), avegetable protein (available from Freeman Industries LLC), corn syrup,and glycerin are admixed to form a liquid blend. The liquid blend isheated to about 54° C. A flavorant is added to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 10.7 parts binder material, 30.7 parts tobacco material, 28.1parts humectant, 1 part emulsifier, 6.9 parts vegetable protein, 14.1parts polydextrose, 3.5 parts corn syrup, 2.1 parts glycerin, 1.8 partssalt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 16

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A humectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), avegetable protein (available from Freeman Industries LLC), corn syrup,and glycerin are admixed to form a liquid blend. The liquid blend isheated to about 54° C. A flavorant is added to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 11.2 parts binder material, 32.3 parts tobacco material, 24.6parts humectant, 1.1 parts emulsifier, 7.2 parts vegetable protein, 14.8parts polydextrose, 3.7 parts corn syrup, 2.2 parts glycerin, 1.9 partssalt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 17

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A vegetable protein (available from Freeman Industries LLC) is combinedwith water. A humectant (available as HYSTAR 3375 from Corn ProductsInternational), an emulsifier (available as DUR-EM 117 from LodersCroklaan), corn syrup, glycerin and the hydrated vegetable protein areadmixed to form a liquid blend. The liquid blend is heated to about 54°C. A flavorant is added to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 9.9 parts binder material, 28.4 parts tobacco material, 26 partshumectant, 0.9 parts emulsifier, 6.5 parts vegetable protein, 21.3 partswater, 13 parts polydextrose, 3.3 parts corn syrup, 2 parts glycerin,1.7 parts salt, 0.2 parts sucralose, and 0.7 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 18

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A humectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), avegetable protein (available from Freeman Industries LLC), corn syrup,and glycerin are admixed to form a liquid blend. The liquid blend isheated to about 54° C. A flavorant is added to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 11.2 parts binder material, 32.3 parts tobacco material, 24.6parts humectant, 1.1 parts emulsifier, 4.6 parts vegetable protein, 14.8parts polydextrose, 3.7 parts corn syrup, 2.2 parts glycerin, 1.9 partssalt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 19

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A gelatin (fish) with a bloom of about 275 is combined with water. Ahumectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), cornsyrup, and glycerin are admixed to form a liquid blend. The liquid blendis heated to about 110° C. The hydrated gelatin and a flavorant areadded to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 9.8 parts binder material, 28 parts tobacco material, 25.6 partshumectant, 0.9 parts emulsifier, 7.6 parts gelatin, 7.6 parts water,12.8 parts polydextrose, 3.2 parts corn syrup, 1.9 parts glycerin, 1.6parts salt, 0.2 parts sucralose, and 0.7 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 20

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A gelatin (fish) with a bloom of about 275 is combined with water. Ahumectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), cornsyrup, and glycerin are admixed to form a liquid blend. The liquid blendis heated to about 110° C. The hydrated gelatin and a flavorant areadded to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 10.4 parts binder material, 27.8 parts tobacco material, 27.3parts humectant, 1 part emulsifier, 4.9 parts gelatin, 4.9 parts water,13.6 parts polydextrose, 3.4 parts corn syrup, 2 parts glycerin, 1.8parts salt, 0.2 parts sucralose, and 0.8 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Example 21

A smokeless tobacco composition suitable for use as a smokeless tobaccoproduct for oral use is provided in the following manner.

A gelatin (fish) with a bloom of about 275 is combined with water. Ahumectant (available as HYSTAR 3375 from Corn Products International),an emulsifier (available as DUR-EM 117 from Loders Croklaan), cornsyrup, and glycerin are admixed to form a liquid blend. The liquid blendis heated to about 143° C. The hydrated gelatin and a flavorant areadded to the heated liquid blend.

A tobacco material blend of two types of tobacco material having anaverage particle size of less than about 100 microns is mixed with abinder material (gum arabic), a salt, a sweetener (sucralose) andpolydextrose powder (available as LITESSE from Danisco A/S) in a Hobartmixing bowl. The liquid blend is added to the Hobart mixing bowlcontaining the tobacco material blend, binder material, salt, sweetener,and polydextrose powder, wherein the ingredients are admixed in Hobartmixer (Model N-50) for about 4-5 minutes at about 120 rpm to form asmokeless tobacco composition. The smokeless tobacco composition ispassed through a meat grinder on the Hobart mixer to incorporate theliquid ingredients into the dry ingredients. The smokeless tobaccocomposition is extruded through a grinder apparatus. Upon extrusion, thesmokeless tobacco composition is placed in a Hobart mixer to form apowder granulation. The mixture of the smokeless tobacco composition isabout 9.8 parts binder material, 28 parts tobacco material, 27.4 partshumectant, 0.9 parts emulsifier, 7.6 parts gelatin, 7.6 parts water,12.8 parts polydextrose, 3.2 parts corn syrup, 1.9 parts glycerin, 1.6parts salt, 0.2 parts sucralose, and 0.7 parts flavorant.

The granulated smokeless tobacco composition is transferred to aninjection mold and compressed at about 103,500 kPa for 1 minute. Themold is a stainless steel two-piece block that is filled with thesmokeless tobacco composition and then compressed via engagement with ahydraulic press unit (Wabach Hydraulic Press, Model 12-102T, Serial2201). The smokeless tobacco composition is removed from the injectionmold after cooling at ambient temperature for about 60 minutes.

Many modifications and other embodiments of the invention will come tomind to one skilled in the art to which this invention pertains havingthe benefit of the teachings presented in the foregoing description.Therefore, it is to be understood that the invention is not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

1. A smokeless tobacco composition configured for insertion into themouth of a user, the smokeless tobacco composition comprising a tobaccomaterial and a polysaccharide filler component.
 2. The smokeless tobaccocomposition of claim 1, wherein the polysaccharide filler componentcomprises polydextrose.
 3. The smokeless tobacco composition of claim 1,wherein the smokeless tobacco composition comprises about 10 weightpercent to about 25 weight percent of the polysaccharide fillercomponent on a dry weight basis.
 4. The smokeless tobacco composition ofclaim 1, further comprising an additional filler component comprising asugar alcohol.
 5. The smokeless tobacco composition of claim 4, whereinthe additional filler component is sorbitol.
 6. The smokeless tobaccocomposition of claim 1, further comprising a binder comprising a watersoluble gum.
 7. The smokeless tobacco composition of claim 6, whereinthe binder is gum arabic.
 8. The smokeless tobacco composition of claim1, further comprising an additive selected from the group consisting offlavorants, binders, emulsifiers, disintegration aids, humectants, andmixtures thereof.
 9. The smokeless tobacco composition of claim 1,wherein the tobacco material has an average particle size of less thanabout 50 microns.
 10. The smokeless tobacco composition of claim 1,wherein the moisture content of the tobacco material is less than about5 percent.
 11. The smokeless tobacco composition of claim 1, wherein thesmokeless tobacco composition is in the form of an injection-moldedpastille.
 12. The smokeless tobacco composition of claim 1, comprising:at least about 20 dry weight percent of tobacco material, based on thetotal weight of the composition; at least about 10 dry weight percent ofpolysaccharide filler component; at least about 10 dry weight percent ofat least one binder; at least about 20 dry weight percent of at leastone humectant; at least about 1 dry weight percent of at least oneemulsifier; at least about 0.1 dry weight percent of at least onesweetener; and at least about 0.5 dry weight percent of at least oneflavorant. 13.-28. (canceled)